Process and apparatus for preparing precut solid water-in-oil emulsion

ABSTRACT

Precut, solid water-in-oil emulsion compositions are prepared by providing a mold having an outer frame and a plurality of configured partitioning plates disposed within the outer frame. The mold is at least partially filled with a fluid form of the emulsion so as to form precuts in the emulsion corresponding to the partitioning plates. The emulsion is then allowed to set. An extrusion die is advanced into the mold. The extrusion die has grooves configured complimentary to the configuration of the partitioning plates so as to receive the partitioning plates therein. The set emulsion is then discharged from the mold by at least partially passing the extrusion die through the mold so as to discharge the set emulsion with the precuts therein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a process for preparing precut fat oroil food in a water-in-oil type emulsion form (referred to hereinaftersimply as fat or oil food in emulsion form) by filling fluid fat or oilfood in emulsion form such as butter, margarine or spread into a moldhaving a partitioning frame and also to an apparatus therefor. A productof fat or oil food in emulsion form prepared according to the inventiveprocess can be readily divided along the preformed cuts even if theproduct is at a relatively low temperature, e.g. immediately after ithas been taken out from a refrigerator or even in a frozen state.Accordingly, the invention provides the product which is useful as tablefat or oil or cooking fat or oil for household consumption or as fat oroil as raw material for commercial consumption.

2. Prior Art

Fat or oil food in emulsion form such as butter, margarine or spread forhousehold use is packaged typically in a unit weight in order of 112.5g˜450 g and usually maintained at a refrigeration temperature ofapproximately 5° C. during its storage or transport.

While the fat or oil food in emulsion form is soft and fluid immediatelyafter it has been prepared, glyceride contained therein is solidifiedupon cooling and results in rapid increase of its hardness. Accordingly,the food presents the state of a hard block immediately after it hasbeen taken out from the refrigerator. The block is too hard to be easilydivided or partially cut off to be used. Particularly in the case ofhard type butter or margarine characterized by its high solid fatcontent index (SFI), the food of this type is usually left for a periodat a room temperature until it becomes sufficiently soft enough to beeasily divided. However, such preheating before the division of the foodresults in poor working efficiency and, even when the remaining portionof the food is cooled and stored again, the deterioration in quality isunavoidable because the surface and other portions have been melted.

Fat or oil commercially consumed in the field of confectionery or bakingtypically to be kneaded into dough is conventionally frozen into a unitblock in order of 10˜30 kg for storage. Also in the case of suchcommercially consumed fat or oil, it is a usual practice to preheat theblock before the portion to be used can be cut off from this block. Suchpractice inevitably results in poor working efficiency.

To solve the problems as have been described above, there have alreadybeen proposed various processes for precutting butter or margarineadapted to be readily divided along the preformed cuts.

For example, there has been disclosed the precut sheet-like butterhaving V-shaped cuts preformed on one surface thereof along which thesheet-like butter can be divided for use (Japanese Utility ModelApplication Disclosure Gazette No. 136180/1987). The process and theapparatus for precutting margarine or the like has been also disclosed(Japanese Patent Publication Gazette No. 17314/1990). According to thisdisclosure, the flow of margarine or the like to be processed is guidedthrough the combing blades provided adjacent to the outlet of the nozzleto form an appropriate number of longitudinal cuts extending along theflow of the fluid margarine or such. Thereafter, the transverse cuts areadditionally formed at appropriate intervals by a plurality of bladesprovided transversely to the flow of the fluid margarine or the like. Inaddition, the process for precutting margarine shape-stabilized at atemperature in a range of 5°˜45° C. has been disclosed (Japanese PatentPublication Gazette No. 27812/1992). According to this disclosure, thecuts are pre-formed on the food at appropriate intervals inlongitudinal, transverse and oblique directions leaving a portion of thethickness cut-free so as to be dividable into appropriately shaped smallpieces.

All the processes for precutting the fat or oil foods in emulsion formdisclosed by these Japanese Utility Model Application Disclosure GazetteNo. 136180/1987, Patent Publication Gazette No. 17314/1990 and PatentPublication Gazette No. 27812/1992 relate to the preparation ofsheet-like fat or oil foods to be kneaded into dough for the preparationof cake or bread. These processes are all similar to each other in thatthe nozzle through which the fat or oil food in emulsion form isextruded is provided at its forward end with the cutter or combingblades. After the longitudinal cuts have been formed by these cutter orcombing blades, the transverse cuts are formed as the food is conveyedby the belt conveyor.

However, table fat or oil and cooking fat or oil for household use areavailable usually in the form of blocks and the process for precuttingthe sheet-like fat or oil foods in emulsion form is not applicablethereto. Specifically, the block-like fat or oil food in emulsion formhas a thickness (i.e., a height) 3˜5 times the average thickness ofsheet-like fat or oil foods in emulsion form. It is assumed for theblock-like food that the longitudinal cuts are formed by using thecutter or combing blades provided on the forward end of the nozzle andthen the transverse cuts are formed as the food is conveyed by the beltconveyor. Said thickness will prevent said transverse cuts from beingformed exactly in vertical direction. Consequently, the resultant shapeand weight of the block-like fat or oil food in emulsion form may becomeuneven.

It is impossible particularly for the commercially consumed block-likefat or oil to employ the above-mentioned process for precutting becausethe block is substantially thicker.

Studying the process for precutting a block of fat or oil food inemulsion form and the apparatus therefor, the inventors found that theproblems as have been described above can be solved by adopting a moldprovided therein with a partitioning frame. The invention is based onthis finding.

SUMMARY OF THE INVENTION

Thus, it is the principal object of the invention to spit provide aprocess for preparing fat or oil food in emulsion form comprising stepsof filling fluid fat or oil food in emulsion form into a mold providedtherein with a partitioning frame and discharging it from the mold by anextrusion die having a configuration corresponding to said partitioningframe of the mold and an apparatus therefor.

According to the invention, fluid fat or oil foods in emulsion form suchas butter, margarine and spread are used as starting materials. Itshould be understood that such starting materials include fat or oilfood in emulsion form which is fluid at the product temperatureimmediately after its preparation. Such starting materials include alsofat or oil food in emulsion form which was cooled in a block-like statebut has been fluidized upon processing by a butter homogenizer or thelike.

The fat or oil food in emulsion form thus fluidized is filled into themold provided therein with the partitioning frame comprising a pluralityof partitioning plates. The outer frame defining the mold may have itsinner peripheral shape selected from, for example, a quadrilateral suchas square, rectangle or trapezoid, and a polygon such as triangle, and aclosed curve composed of a straight line and a curve such as sector. Thepartitioning frame provided within the mold may be arranged so as todefine a desired shape of each partition selected from various shapes,for example, square, rectangle, trapezoid and triangle, as in the caseof the mold, so far as a plurality of partitions are provided by thepartitioning plates. Connection of the nozzle to the mold may beimplemented by mounting the nozzle configured substantially inconformity with the outer frame of the mold on the bottom or the top ofthe mold in close contact with each other.

The height of the partitioning frame may be equal to or lower (shorter)than that of the outer frame of the mold. When the partitioning framehas the same height as that of the mold, the partitioning frame isassembled to the mold so that the upper and lower ends of these twocomponents may be aligned with each other. Such arrangement allows thefat or oil food in emulsion form filled into the mold to be formed withthe precuts fully extending from the top to the bottom thereof. When theheight of the partitioning frame is shorter than that of the mold, thepartitioning frame is assembled to the mold at the location shiftedinward from the upper end or the lower end of the mold. Such arrangementallows the fat or oil food in emulsion form to have a precut-freeportion adjacent to its upper or lower end.

The mold provided therein with the partitioning frame in the manner ashas been described above is filled with the fluid fat or oil food inemulsion form. Then the fat or oil food in emulsion form, now having theprecuts formed by the partitioning frame, is transferred together withthe mold from the filling station to the discharging station by transfermeans such as a slide plate or a turntable. During this transfer, anexcessive portion of the fat or oil food in emulsion form bulging outfrom the bottom of the mold is leveled off by using a thin board or thelike to make the mold content uniform. The fat or oil food in emulsionform having its quantity made uniform is then discharged from the moldby an extrusion die. The extrusion die is provided with grooves arrangedin the same configuration as said partitioning frame and adapted toreceive the partitioning plates in the direction of extrusion. The upperend of the fat or oil food in emulsion form is leveled off in a planeperpendicular to the direction of extrusion by a wire cutter means suchas a piano wire, as the fat or oil food in emulsion form is dischargedfrom the mold.

The outer peripheral shape of the extrusion die as a whole correspondsto the inner peripheral shape of the mold's outer frame. The gap definedbetween the outer peripheral wall of the extrusion die and the innerperipheral wall of the mold is preferably adjusted to be as narrow aspossible so that these two walls may be slidably contacted by eachother. It is also important to define the width of said grooves providedin the extrusion die to receive partitioning plates of the mold so thatthe gap defined between each partitioning plate and the adjacent groovewall may be maintained as narrow as possible.

While the extrusion die can be extruded either from above or from below,the mold, the process can be advantageously simplified when it isextruded from above the mold to discharge the fat or oil food inemulsion form directly onto wrapping paper or the like.

Now the relative position of the mold and the extrusion die establishedwhen the extrusion die is provided above the mold and the fat or oilfood in emulsion form is filled into the mold from below will bediscussed.

When the partitioning frame lower than the height of the outer frame ofthe mold is assembled to the mold with the lower end of saidpartitioning frame lying at the location shifted upward from the lowerend of the mold, a difference in level is defined between the lower endof the partitioning frame and the lower end of the mold. A butter pumpor the like is actuated to feed the fat or oil food in emulsion formthrough the nozzle into the mold immediately after the bottom of theextrusion die has reached the bottom of the mold. The extrusion dieserves as a top plate and is progressively forced up as the fat or oilfood in emulsion form is filled into the mold. When a predeterminedquantity has been filled into the mold, the mold thus filled with thefat or oil food in emulsion form is transferred from the filling stationto the discharging station. During this transfer, the excessive portionof the fat or oil food in emulsion form bulging out from the bottom ofthe mold is leveled off by the thin board or the like to make the moldcontent uniform. At the discharging station, the fat or oil food inemulsion form is discharged from the mold by the extrusion die, then itstop end is leveled off by a wire cutter means such as a piano wire andplaced on wrapping paper laid below the mold. The mold from which thefat or oil food in emulsion form has been discharged and the extrusiondie associated therewith automatically return to the filling station andthe process as has been mentioned above is repeated.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be more fully understood with consideration to thespecific embodiments described in detail with reference to theaccompanying drawings, in which:

FIG. 1 is an exploded perspective view exemplarily showing a combinationof extrusion die and mold according to the invention;

FIG. 2 is a perspective view exemplarily showing the product obtained byusing these extrusion die and mold;

FIG. 3 is a schematic side sectional view illustrating a step of theinventive process during which the mold is transferred by a slide plate;

FIG. 4 is a schematic side sectional view illustrating the positiontaken by the inventive apparatus immediately before the mold is filledwith fat or oil food in emulsion form;

FIG. 5 is a schematic side sectional view illustrating the positiontaken by the inventive apparatus immediately after the mold has beenfilled with fat or oil food in emulsion form;

FIG. 6 is a schematic side sectional view illustrating the positiontaken by the inventive apparatus immediately after the mold filled withfat or oil food in emulsion form has been transferred to a dischargingstation;

FIG. 7 is a schematic side sectional view illustrating the inventiveapparatus as it is discharging fat or oil food in emulsion form from themold;

FIG. 8 is an exploded perspective view showing a variant in combinationof extrusion die and mold according to the invention;

FIG. 9 is a perspective view showing the product obtained by using thecombination of extrusion die and mold shown by FIG. 8;

FIG. 10 is a perspective view showing a specific embodiment of the moldcomprising an outer frame and a partitioning frame both dimensioned in asame height;

FIG. 11 is a perspective view showing the product obtained by using themold shown by FIG. 10;

FIG. 12 is an exploded perspective view showing a product of fat or oilfood in emulsion form having groove like cavities parallelly arranged inits longitudinally middle region to receive a knife edge insertedthereinto and a combination of extrusion die and mold used to preparethis product;

FIG. 13 is a perspective diagram illustrating the manner in which theproduct shown by FIG. 12 is packaged with wrapping paper;

FIG. 14 is an exploded perspective view showing a product of fat or oilfood in emulsion form having groove-like cavities parallelly arranged ontransversely opposite sides adapted to receive a knife edge and acombination of extrusion die and mold used to prepare this product;

FIG. 15 is a perspective diagram illustrating the manner in which theproduct shown by FIG. 14 is packaged with wrapping paper;

FIG. 16 is a perspective diagram illustrating the manner in which theproduct obtained according to the invention but different from theproduct shown by FIG. 15 is packaged with wrapping paper;

FIG. 17 is a diagram illustrating the molds placed on a turning table asviewed from above the top of the inventive apparatus;

FIG. 18 is a diagram illustrating the molds placed on a turning tableequipped with lift means for the extrusion die as viewed from above thetop of the inventive apparatus;

FIG. 19 is a schematic side sectional view corresponding to FIG. 18;

FIG. 20 is a horizontal sectional view showing the partitioning frameaccording to the invention; and

FIG. 21 is a horizontal sectional view showing a variant in thepartitioning frame according to the invention.

THE MOST PREFERRED EMBODIMENT OF THE INVENTION

Details of the invention will be better understood from the followingdescription of several embodiments described below.

Referring to FIG. 1, a mold (M) comprises an outer frame (1) and apartitioning frame (3) arranged inside said outer frame (1) by aplurality of partitioning plates (2) in parallel crosses. An extrusiondie (4) is provided with grooves (5) adapted to receive the partitioningplates (2) of the partitioning frame (3) as the extrusion die (4) isadvanced.

The partitioning frame (3) is shown by FIG. 1 to be lower than the outerframe (1).

To obtain a product shown by FIG. 2 by using such mold (M), the mold (M)is placed on a slide plate (7) which is, in turn, slidably moved on astand (6), as will be apparent from FIG. 3.

The slide plate (7) is provided with a filling port (8) dimensioned inconformity with a bottom of the mold (M) and a nozzle (9) is provided ona lower side of the stand (6) in alignment with said filling port (8).Fat or oil food in emulsion form is fed by a feed pump (10) to thenozzle (9) via a pipe (11).

Referring to FIG. 4, the extrusion die (4) serving as a top plate isprogressively force up as fat or oil food in emulsion form is fed fromthe nozzle (9) through the filling port (8) of the slide plate (7) intothe mold (M). The mold (M) having been filled with a predeterminedquantity of fat or oil food in emulsion form is transferred by the slideplate (7) from a filling station shown by FIG. 5 to a dischargingstation shown by FIG. 6. During this transfer, the excessive quantity offat or oil food in emulsion form bulging out from the mold bottom isleveled off by the stand (6) to make the mold content uniform.

Referring to FIG. 7, the fat or oil food in emulsion form is extrudedfrom the mold (M) as the extrusion die (4) descends and discharged ontowrapping paper (14) laid below the mold (M) after its top end has beenleveled off by a wire cutter means (12) such as piano wire.

The mold (M) from which the fat or oil food in emulsion form has beendischarged automatically returns together with the associated extrusiondie (4) to the filling station in preparation for the next cycle of theprocess.

In this specific embodiment, the partitioning frame (3) lower than theouter frame (1) of the mold (M) is assembled to the mold (M) with thelower end of the frame (3) being positioned at a level shifted upwardfrom the bottom of the mold (M). In other words, the partitioning frame(3) is assembled to the mold (M) so as to define a difference in levelbetween the lower end of the frame (3) and the bottom of the mold (M).

Consequently, a product (a) is formed in its upper portion with cuts(13) arranged in parallel crosses, leaving a lower portion (a') havingnone of such cuts (13), as shown by FIG. 2.

In this embodiment, the partitioning frame (3) serves also as a stopperpreventing the extrusion die (4) from fully descending within the mold(M). Accordingly, the grooves (5) of the extrusion die (4) terminate atan intermediate level(4a) between the heights of the partitioning frame(3) and the outer frame (1) of the mold (M).

The product (a) shown by FIG. 2 has cuts (13) not fully extending to itsbottom and respective blocks partitioned by the frame (3) are notdisjointed. This is for the reason that the height of the partitioningframe (3) is lower than the height of the mold (M). More specifically,the partitioning frame (3) is assembled to the outer frame (1) of themold (M) at a location shifted inward from the bottom of the mold (M).As a result, the lower portion of the product shown by FIG. 2 is freefrom formation of the cuts (13).

Leaving a portion of the product free from formation of the precuts isachieved also by arranging the partitioning plates (2) in a specialconfiguration. Specifically, the partitioning plates (2) extending fromthe outer frame (1) of the mold (M) may define interrupted lines asviewed in a section of the partitioning frame (3) taken along a planeperpendicular to the direction of extrusion, as shown by FIGS. 20 and21. Particularly, the partitioning plates (2) may be thickened in theproximity of the outer frame (1) to stabilize the frame (2) duringfeed/discharge of the food and to facilitate the product to be easilydivided in use.

While the partitioning plates (2) have been described above as they areof a same height, it is not essential to dimension all the partitioningplates (2) in a uniform height. For example, it is possible to dimensiononly several plates (2) in conformity with the height of the mold (M)Appropriate non-uniformity in the height of the plates (2) will berather advantageous in some aspects. Namely, a variety is obtained inlength as well as distribution of the precuts depending on theparticular types of the product.

Depending on the position at which the nozzle is mounted, it is alsopossible to assemble the frame (3) to the outer frame (1) at a locationshifted inward from the top of the mold (M). Such arrangement results ina product having its upper portion free from formation of the precuts(13) in contrast with the product shown by FIG. 2.

Connection of the nozzle (9) to the mold (M) is implemented by attachingthe nozzle (9) having a shape substantially identical to the outer frame(1) of the mold (M)to top or bottom side of the mold (M). When it isdesired to extrude the product directly onto wrapping paper (14) or thelike, the extrusion is preferably performed from above so that theproduct may fall by its own gravity on wrapping paper (14) or the like.This is advantageous in simplifying the process.

When the frame (3) has the same height as that of the mold (M), theframe (3) is attached to the mold (M) so that the upper and lower endsof these two components may be aligned with each other. As a result, theproduct filled into the mold (M) can be provided with the precuts fullyextending from the top to the bottom of this product.

The outer frame (1) of the mold (M) may have its inner peripheral shapeselected from, for example, a quadrilateral such as square, rectangle ortrapezoid, and a polygon such as triangle, and a closed curve composedof a straight line and a curve such as a sector. The partitioning frame(3) provided inside the mold (M) may be also arranged so as to definethe partitions of a desired shape. As in the case of the mold, the shapemay be selected from, for example, square, rectangle, trapezoid,triangle etc., so far as a plurality of partitions are formed by thepartitioning plates.

A specific embodiment shown by FIG. 8 comprises the partitioning frame(3) formed by the partitioning plates (2) arranged so as to define thepartitions individually shaped in a trapezoid. Such arrangement resultsin a product presenting the trapezoidal pillar-shaped partitions andleaving a portion (a') of its thickness free from formation of theprecuts (13), as shown in FIG. 9.

FIG. 10 shows the mold (M) with the outer frame (1) having the sameheight as the partitioning frame (3). Use of this mold (M) results in aproduct provided with the precuts (13) fully extending from the top tothe bottom of the product as shown by FIG. 11.

The product provided with such fully extending precuts can be readilydivided along the precuts even in its frozen state.

Conventionally it has been a practice to freeze the far or oil food inemulsion form for storage in the form of unit block weighingapproximately 10˜30 kg at a temperature in a range of -18°˜-20° C.Accordingly, the block has had to be left at a room temperature in arange of 5°˜15° C. for 10˜20 days until it is completely preheated andthawed before use. The product provided with the precuts, on the otherhand, can be completely preheated and thawed under the same temperaturecondition in approximately 3˜5 days after frozen and divided, on theassumption that its total weight corresponds to the weight of said unitblock.

Consequently, the working efficiency can be significantly improved andat the same time the utilizing efficiency of the refrigerator space isalso improved. After the thawing process, the product obtained accordingto the invention can be used in the same manner as the conventionalproduct which is frozen for storage in the form of a unit block. Forexample, the product obtained according to the invention can be kneadedinto dough or the like as material fat or oil or as commerciallyconsumed fat or oil in the field of confectionery or baking. It is alsopossible, if desired, to use the product after it has been rekneaded.The fat or oil food is in emulsion form and thus rekneaded can beprocessed to form a block weighing approximately 112.5˜450 kg. Suchblock of fat or oil food in emulsion form may be provided with theprecuts and offered as the table fat or oil or the cooking fat or oilfor household use.

FIG. 12 shows a case in which a height of the partitioning frame (3) islower than that of the outer frame (1) of the mold (M). A plurality ofpartitioning plates (2) are parallelly arranged inside the outer frame(1). Each of the partitioning plates (2) is formed at its longitudinallyintermediate portion with a relatively thick prominence (2a) fullyextending from top to bottom of this plate (2). The extrusion die (4) iscorrespondingly formed with grooves (5) adapted to receive therespective partitioning plates (2) of the partitioning frame (3).Accordingly, each of the grooves (5) is formed with a cavity (4b)adapted to receive said prominence (2a).

Bottoms (4a) of the grooves (5) lie at a level still leaving a partialthickness of the extrusion die and serve as stoppers for the extrusiondie (4) being descended by resting on the upper ends of the respectivepartitioning plates (2). Consequently, the product (a) as illustratedbelow the mold (M) is obtained as the fat or oil food in emulsion formis extruded by the extrusion die (4) from the mold (M). This product (a)has precuts or splits (20) fully extending from its upper end to itslower end and intermediate length of each split (20) defines arelatively wide cavity (21).

When the product (a) is placed on wrapping paper (14) and packagedtherewith, the respective partitions of the product (a) are put closelyone to another so that the splits (20) are practically invisible, asshown by FIG. 13. Packaging in such manner is effective to prevent theproduct (a) from being disjointed during storage.

In use, the product can be readily divided by inserting a knife or thelike into the cavity (21) after the product has been unwrapped.

The mold (M) shown by FIG. 14 is similar to the mold (M) shown by FIG.12 except that each partitioning plate (2) is provided at itstransversely opposite ends with a relatively thick prominence (2a) fullyextending from the upper end to the lower end of the partitioning plate(2).

This mold (M) provides a product (a) having relatively wide grooves (22)vertically extending in transversely opposite surfaces of the product(a) and the splits (20) extending between the respective pairs of suchgrooves (22), as will be seen in lower portion of FIG. 14.

In packaging, the product (a) is placed on wrapping paper (14) with saidgrooves (22) parallelly arranged on the transversely opposite sides asshown by FIG. 15. Also in this case, the respective partitions are putclosely so that the splits are practically invisible.

Depending on the ratio between lengths of respective sides defining thebottom and the height of the mold (M), it is also possible to place theproduct (a) on wrapping paper (14) and to package it so that the grooves(22) are parallelly arranged on vertically opposite sides of the product(a), as shown by FIG. 16.

FIG. 17 illustrates a process for continuously preparing the product byutilizing a turntable (15) adapted to be stepwise rotated by every 90°.More specifically, four steps of filling fat or oil food in emulsionform into the mold→transfer→discharge/precut of fat or oil food inemulsion form→transfer are repeated.

The mold (M) is filled by a feeder (16) with fat or oil food in emulsionform as the turntable (15) is rotated by 90° to station A. The mold (M)thus filled with fat or oil food in emulsion form is transferred tostation B and held here as the turntable (15) is further rotated by 90°.Then, the turntable (15) is further rotated by 90° and thereby the mold(M) is transferred to station C where fat or oil food in emulsion formis discharged from the mold (M). This empty mold (M) is transferred tostation D as the turntable (15) is further rotated by 90° and held hereand then returns to the initial station A as the turntable (15) isrotated by a final 90°. While the feeder (16) of fat or oil food inemulsion form is illustrated in an enlarged scale for convenience, thisfeeder (16) is provided below station A.

FIGS. 18 and 19 illustrate the turntable (15) adapted to be rotatedstepwise by every 90 just like the turntable (15) shown by FIG. 17. Foursteps of filling→transfer→discharge/precut→transfer are repeated toachieve the process for continuously preparing the precut unit productsof fat or oil food in emulsion form.

Specifically, the mold (M) is filled with fat or oil food in emulsionform at station A and the mold (M) thus filled with fat or oil food inemulsion form is held at station B. Then the discharge/precut isperformed at station C and the empty mold (M) is transferred again tostation A.

A rod (17) of the extrusion die (4) is provided with a cam roller(19)which is biased downward under the effect of a spring (not shown) to bemaintained in contact with a stationary guide (18). Thus, the rod (17)is vertically moved following a profile of said guide (18) as theturntable (15) is rotated.

In an arrangement illustrated by FIG. 19, also the feeder (16) of fat oroil food in emulsion form provided below the mold (M) is a partitioningframe (3b) in operatively associated with the partitioning frame (3).Such arrangement allows fat or oil food in emulsion form to be smoothlyfed into the mold (M) overlying the feeder (16).

In both arrangements illustrated by FIGS. 17 and 18, the wire cuttermeans (12) is used to level off the top end of the fat or oil food inemulsion form at the discharge/precut station.

The turntable (15) is stepwise rotated every 90° and each cycle of theprocess is completed by four steps in the arrangement illustrated byFIGS. 17 and 18. However, the unit angle of rotation is not limited to90°. For example, two steps of filling and discharging or four steps offilling, transfer, discharge/precut and transfer can be achieved byrotation of a single unit angle. In this case, the turntable will bestepwise rotated by every 360/2n°. Thus the unit angle of rotation canbe selectively set depending on the particular placement of therespective stations (It should be understood that n represents aninteger).

While the case has been described above in which there are provided asingle feed station and a single discharge/precut station, respectively,there may be provided plural feed stations as well as pluraldischarge/precut stations. It is assumed, for example, that the unitangle of rotation is set to 45° and there are provided a pair of feedstations and a pair of discharge/precut stations. In this case, saidfour steps will be completed as the turntable is rotated by 180° andthereby the processing capability of the single turntable (15) will bedoubled.

Four experimental examples utilizing the invention will be describedbelow.

EXAMPLE 1

The mold (M) of FIG. 10 was mounted on the turntable (15) shown by FIG.19 and butter prepared by the conventional process as divided intorectangular blocks.

The mold (M) was filled with butter and the turntable (15) was stepwiserotated by every 90°. In this manner, the steps offilling→transfer→discharge/precut→transfer were repeated and therebyprecut products were continuously obtained.

As means to precut the butter, the mold (M), the extrusion die (4) andthe partitioning frame shown by FIGS. 10 and 19 were employed. Toenhance filling efficiency, the partitioning frame (3b) shown by FIG. 19was provided on the forward end of the butter feeder (16), i.e., belowthe mold (M). The partitioning frame (3a) was dimensioned to have ashort side of 6.5 cm and a long side of 9.5 cm and divided by thepartitioning plates (2) having a height of 6 cm into 9 partitions. Eachpartition had a rectangular bottom defined by a short side of 2 cm and along side of 3 cm.

The extrusion die (4) was dimensioned to be slidable movable in thevertical direction in contact with the inner surface of the partitioningframe (3a). To achieve this, the width of each groove was dimensioned tobe wider than the thickness of the partitioning plates (2) by 0.4 mm.The lower partitioning frame (3b) presented the same cross-sectionalarea as the upper partitioning frame (3a) and was divided by thepartitioning plates (2) having a height of 5 cm into nine partitions.During the step of filling the mold (M) with butter, these upper andlower partitioning frames (3a) (3b) were operatively associated witheach other in close contact.

Butter prepared by the conventional process was fed by the screw feederinto the mold (M). The extrusion die (4) was moved upward as the mold(M) was filled with butter. The position of the stopper means wasadjusted so that the extrusion die (4) may be stopped when it was movedupward by 5.4 cm and thereby the weight of butter per unit partitionreached 30 g. After the mold (M) had been filled with a predeterminedquantity of butter, the turntable (15) was rotated by 90° and the nextmold (M) was filled with butter. The turn table was further rotated by90° to the position spaced by 180° from the filling station, at whichthe extrusion die (4) was forcibly lowered to discharge butter from themold (M). After butter had been completely extruded onto wrapping paper(14), the upper end of butter was cut off from the extrusion die (4) bythe wire cutter (12) and packaged with the precuts (13) separating therespective partitions which are close to one another.

This product of butter was divided into nine partitions by the grooves(5) having the same width as the thickness of the partitioning plates(2). Both the shape and the weight of butter per unit partition wassame. The weight of butter per unit partition was uniformly 30 g.

The extrusion die (4) being slidably movable in contact with thepartitioning frames (3a) (3b) allowed the product of butter to bedivided in uniform shape and weight.

EXAMPLE 2

The extrusion die (4) and the mold (M) of FIG. 8 were mounted on theturntable (15) of FIG. 19 to obtain a product divided into trapezoidalpillars but having a portion (a') left to be free from formation of theprecuts. Butter prepared by the conventional process and hardened wasfluidized by the butter homogenizer.

Butter was filled into the mold (M). The turntable was stepwise rotatedby every 90°. Specifically, four steps offilling→transfer→discharge/precut→transfer were repeated and thereby theprecut product was continuously obtained.

The extrusion die (4) and the partitioning frame (3a) shown by FIG. 8were used to form the precuts in the product of butter. The partitioningframe (3a) was defined to have a short side of 6.5 cm and a long side of9.5 cm and divided by the partitioning plates (2) having a height of 4into eight partitions. The partitioning plates (2) forming thepartitioning frame (3a) were supported at a level lying 5 mm above thelower end of the partitioning frame (3). Each partition presented atrapezoidal cross-section defined by a top side of 0.6 cm, a bottom sideof 2.35 cm and a height of 4.6 cm. The size of the extrusion die (4) wasselected so as to be movable in slidable contact with the inner surfacesof the partitioning frame (3a) in vertical direction. To achieve this,the grooves (5) were dimensioned to have a width larger than thethickness of the partitioning plates (2) by 0.4 mm.

Butter prepared by the conventional process was fed by the screw feederinto the mold (M). The extrusion die (4) was filled with butter. Theposition of the stopper means was adjusted so that the extrusion die (4)may be stopped when it was moved upward by 4 cm and thereby the weightof butter per unit partition reached 25 g. After the mold (M) had beenfilled with a predetermined quantity of butter, the turntable (15) wasrotated by 90° and the next mold (M) was filled with butter. Theturntable (15) was further rotated by 90° to the position spaced by 180°from the filling station, at which the extrusion die (4) was forciblylowered to discharge butter from the mold (M). After butter had beencompletely extruded onto wrapping paper (14), the upper end of butterwas cut off from the extrusion die (4) by the wire cutter (12) andpackaged.

This product of butter was divided into eight partitions by the grooves(5) having the same width as the thickness of the partitioning plates(2) but had a lower portion left to be free from formation of theprecuts. The portion having no precut was readily split. Both the shapeand the weight of butter per unit partition thus split was same. Theweight of butter per unit partition was uniformly 25 g.

The product was thus partitioned by the precuts in uniform shape andweight leaving a portion of its thickness free from formation of theprecuts. This was achieved by providing a difference in level betweenthe bottoms of the partition plates (2) and the surface of the turntable(15). The extrusion die (4) slidably movable in contact with the innersurfaces of the partitioning frame (3a) also contributed to thispurpose.

EXAMPLE 3

The same feeder (16), extrusion die (4) and partitioning frames (3a)(3b) as those used in EXAMPLE 1 were used. The precuts were formed aftermargarine of hard type prepared by the conventional process and hardenedhad been fluidized by the butter homogenizer.

After the mold (M) had been filled with margarine, the turntable (15)was stepwise rotated. A lifting mechanism adapted to lift the extrusiondie (4) was provided on the way to the discharge station.

Fluidized margarine was fed by the screw feeder into the mold (M). Theextrusion die (4) was moved upward as the mold (M) was filled withmargarine. The stopper means was adjusted so that the extrusion die (4)may be stopped when it was moved upward by 2 cm and thereby the mold isfilled with a predetermined quantity of margarine, and the turntable(15) was rotated by 90°. During this rotation, the extrusion die (4) wasfurther moved upward by 5 mm and the bottom of the extrusion die (4) wasspaced from the bottom of the turntable (15) by 2.5 cm. Simultaneously,margarine filling the mold (M) was also moved upward and the lowerportions of the partitioning plates (2) were exposed out of themargarine.

At the position angularly spaced from the filling station, the extrusiondie (4) was forcibly lowered to discharge margarine from the mold (M).After margarine had been completely extruded onto wrapping paper (14),the top end of margarine was cut off from the extrusion die (4) by thewire cutter (12). Then the product was packaged with the partitionsclose to one another so that the precuts (13) were practicallyinvisible.

This product of margarine was divided into nine partitions by thegrooves (5) having the same width as the thickness of the partitioningplates (2). Both the shape and the weight of margarine per unitpartition were uniform and the weight per unit partition was 11 g.

Division of margarine into the partitions being uniform in both theshape and the weight was achieved by the unique arrangement as follows:The extrusion die (4) was lifted to a level higher than the level duringthe step of filling as the extrusion die (4) was transferred by rotationof the turntable (15). Thereby the extrusion die (4) pulled margarine upuntil the bottoms of the partitioning plates (2) was exposed as theextrusion die (4) was moved in slidable contact with the inner surfacesof the partitioning frame (3a).

EXAMPLE 4

The mold (M) of FIG. 10 was mounted on the slide plate (7) shown by FIG.3 and precut block butter was prepared from butter prepared by theconventional process.

At the filling station, the mold (M) was filled from its underside withbutter prepared by the conventional process. Then, the mold (M) wastransferred to the discharge station at which butter was extruded by theextrusion die (4). Four steps offilling→transfer→discharge/precut→transfer were repeated byreciprocation of the slide plate (7) and thereby precut butter wascontinuously obtained.

More specifically, the partitioning frame (3) divided into ninepartitions each configured in a square defined by each side of 11 cm isassembled inside the outer frame (1) to form the mold (M). The grooves(5) formed in the extrusion die (4) had a width larger than thethickness of the partitioning plates (2) by 1 mm.

The mold (M) within which the extrusion die (4) had, been lowered to thebottom of the mold (M) was placed at the filling station and butter wasfed into the mold (M) by the feed pump (10). The extrusion die (4) wasmoved upward as it was filled with butter. The stopper means wasadjusted so that the extrusion die (4) may be stopped when a level of19.5 cm was reached and the total weight of butter reached 20 kg. Afterthe mold (M) was filled with a predetermined quantity of butter, theslide plate (7) was transferred to the discharge station. At thisstation, the extrusion die (4) was forcibly lowered to discharge butterfrom the mold (M) onto wrapping paper (14). The top end of butter wascut off by the wire cutter (12) and packaged as an individual product.

The product of butter obtained in this manner had nine partitionsdivided by the grooves (5) having the same width as the thickness of thepartitioning plates (2). The weight of butter per unit partition was ina range of 2.23 kg to 2.25 kg.

The product was frozen at a temperature of -15° C. in the refrigerator.Thereafter the product in its frozen state as was unwrapped. It wasfound that the product still in the frozen state can be easily dividedinto the respective partitions.

The product thus divided was packaged again with wrapping paper (14) andpreheated in a pyrostat at a temperature of 13° C. 32 hours after, thetemperature at the core portion of each block was determined to besubstantially uniform in a range of 12.6° C. to 12.8° C. At suchtemperature, each block of butter was sufficiently soft enough to bereadily cut.

For the purpose of comparison, non-precut block butter of 20 kg wascompletely frozen and then preheated under the same condition. It wasfound that nine days are necessary for the core portion of thisnon-precut block butter to reach said temperature (12.6° C.˜12.8° C.).

As will be apparent from this comparison, it is difficult for un-precutblock butter to be preheated within a reasonably short period. Thisnecessarily decreases the working efficiency as well as the utilizingefficiency of refrigerator space. In contrast with this, precut butterprovided by the invention is readily split even in its frozen state. Inaddition, the invention allows the preheating required for thawing to beachieved within a reasonably short period. These advantages areextremely valuable in practical use.

It should be understood that the invention is not limited to thespecific embodiments as have been described hereinabove but defined bythe appended claims. For example, the type of precuts formed in theproduct is selective. Specifically, the precuts may fully extend fromthe top to the bottom of the product or partially extend so as to leavethe upper or lower portion of the product to be free from formation ofthe precuts. Such selection depends on the configuration of thepartitioning frame (3) relative to the mold (M) and the manner in whichthe frame (3) is attached to the mold (M). Accordingly, these designingfactors may be optionally modified without departing from the spirit andscope of the invention.

Industrial Use

The invention allows the block-like product of fat or oil food inemulsion form to be easily formed with precuts. The product thus formedwith the precuts can be readily divided even at a low temperatureimmediately after it has been taken out from the refrigerator or even inits frozen state. In this way, just the quantity to be used can bedivided off. The product can be readily split while it is still in itshard state at a low temperature, and therefore it is unnecessary at allto leave it at a room temperature and to wait long until it is soft.This means that there is no apprehension that a remaining portion of theproduct might be deteriorated in its quality.

Block-like butter or margarine for household use has conventionally beenoffered in the form of a block and could not be formed with the precutsas in the case of sheet-like products. The invention has effectivelysolved this problem.

As will be apparent from the foregoing description, the invention allowsthe bulky product for commercial consumption to be easily split. Thiscontributes to quality preservation, improved working efficiency andefficient utilization of storage space. The invention also provides suchadvantages to household uses.

What is claimed is:
 1. A process for preparing a precut, solidwater-in-oil emulsion, comprising:1) providing a mold having an outerframe and a plurality of configured partitioning plates disposed withinthe outer frame; 2) at least partially filling the mold with a fluidform of the emulsion so as to form precuts in the emulsion correspondingto the partitioning plates; 3) allowing the emulsion to set; 4)advancing an extrusion die into the mold the extrusion die havinggrooves configured complimentary to the configuration of thepartitioning plates so as to receive the partitioning plates therein;and 5) discharging the set emulsion from the mold by at least partiallypassing the extrusion die through the mold so as to discharge the setemulsion with the precuts therein.
 2. The process of claim 1, whereinthe emulsion is butter or margarine.
 3. The process of claim 1, whereinthe set discharged emulsion is disposed on a wrapping for wrappingthereof.
 4. The process of claim 3, wherein the extrusion die advancesinto the mold from an above vertical position and the discharged setemulsion drops into the wrapping by gravity.
 5. The process of claim 1,wherein the filling is at a filling station and the discharging is at adischarge station and after the filling of the mold, the mold istransferred to the discharge station.
 6. The process of claim 5, whereinthe mold is on a turn table and the mold is transferred to the dischargestation by rotation of the turn table.
 7. The process of claim 6,wherein there are a plurality of filling stations and a plurality ofdischarge stations and the turn table is rotated from a filling stationto a discharge station.
 8. The process of claim 1, wherein thepartitioning plates are arranged such that the precuts extend through adimension of the set emulsion and the discharged set emulsion is in theform of a plurality of individual precut portions.
 9. The process ofclaim 1, wherein the partitioning plates are arranged such that theprecuts do not extend through a dimension of the set emulsion and thedischarged emulsion is in the form of a single molding with precutstherein.
 10. The process of claim 1, wherein the emulsion is set byfreezing.
 11. An apparatus for preparing a precut, solid water-in-oilemulsion, comprising:1) a mold having an outer frame and a plurality ofconfigured partitioning plates disposed within the outer frame; 2)filling means for at least partially filling the mold with a fluid formof the emulsion so as to form precuts in the emulsion corresponding tothe partitioning plates; 3) an extrusion die having grooves configuredcomplimentary to the configuration of the partitioning plates so as toreceive the partitioning plates therein; and 4) discharge means for atleast partially moving the extrusion die through the mold so as todischarge a set form of the emulsion with the precuts from the mold. 12.The apparatus of claim 11, wherein the filling means is a nozzle. 13.The apparatus of claim 11, wherein the partitioning plates haveprominences extending along a height of the partitioning plates.
 14. Theapparatus of claim 11, wherein at least some of the partitioning plateshave a heightless than a height of the outer frame such that a portionof the emulsion in the mold is free from precuts.
 15. The apparatus ofclaim 11, wherein the grooves have a depth in the extrusion die largerthan heights of the partitioning plates whereby the partitioning platesconstitute a stop for the extrusion die.
 16. The apparatus of claim 11,wherein the filling means is a feeder underlying the mold and operablyconnected thereto.
 17. The apparatus of claim 11, wherein the fillingmeans is at a filling station and the discharge means is at a dischargestation and after filling the mold, the mold is transferred to thedischarge station.
 18. The apparatus of claim 17, wherein the mold is ona slide plate which is movable from the filling station to the dischargestation.
 19. The apparatus of claim 17, wherein the mold is on a turntable and the turn table is rotatable from the filling station to thedischarge station.
 20. The apparatus of claim 18, including a levelingmeans to remove excess emulsion from the mold as the mold is transferredfrom the filling station to the discharge station..
 21. The apparatus ofclaim 17, including a leveling means to remove excess emulsion from themold as the mold is transferred from the filling station to thedischarge station.
 22. The apparatus of claim 19, wherein a guide railspaced above the turn table is configured for moving the extrusion dieinto the mold at the discharge station, for discharging the precut setemulsion and for moving the extrusion die out of the mold after theprecut set emulsion is discharged from the mold, as the turn table isrotated.
 23. The apparatus of claim 16, wherein a partitioning frame isalso provided within the feeder underlying the mold, so a s to beoperatively associated with the partitioning frame within the mold.